Reusable envelope tray system

ABSTRACT

A reusable envelope tray system includes a stacking tray with linear structural corrugations and a support unit. The tray bottom has parallel side fold lines extending along the corrugations and parallel end fold lines transverse to the corrugations. A sidewall extends upwardly from each bottom side fold line, and an end wall extends upwardly from each bottom end fold line. Each end wall has an outer portion connected to the bottom wall and an inner portion connected to the outer portion. Fold lines connect the inner and outer portions to provide a bearing surface during stacking. The outer portion includes a hand hole and the inner portion includes a return hinge extending transverse to the corrugations and reachable through the hand hole. The hinge allows bending of the inner portion under folding assembly/disassembly of the tray. The support unit has upstanding posts received in apertures on the tray bottom.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. 119(e) and 37 C.F.R. 1.78(a)(4) based upon copending U.S. Provisional Application Ser. No. 61/333,090 for REUSABLE ENVELOPE TRAY filed May 10, 2010, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present disclosure is broadly concerned with a reusable envelope container system. More particularly, it is concerned with a system having an envelope tray and support structure that enable the tray to be easily and repeatedly assembled without the need for adhesive or other fasteners, and easily disassembled to a flat condition for efficient storage and access for reuse.

Envelope manufacturing is a highly automated process in which the envelopes are cut from a paper blank or web by a die press or cutting unit and then folded and gummed. The envelopes generally reach the exit tray or table of the envelope machine with the seam adhesive still wet. The envelopes must be packed and stored resting on edge in order to avoid deformation, which can occur if they are stored flat. Deformation spoils envelopes for use with automatic inserting equipment because the deformed envelopes tend to jam the equipment.

Typically, newly manufactured envelopes are accumulated into stacks, compressed, and packed on edge in containers such as boxes, cartons or trays for delivery to customers or to an inserter/mailer firm that uses automated equipment to stuff the envelopes. Such containers must be sturdy to protect the envelopes and withstand stacking, and they must present a smooth, unobstructed interior surface so that the envelopes are not deformed. Corrugated containers are generally favored for delivery of envelopes to commercial users such as inserter/mailer firms that use automated equipment to stuff the envelopes.

This packaging system is expensive, inefficient and not environmentally friendly. The corrugated containers are expensive and take up space in the area of the envelope and inserter machinery. Disposal of the containers is wasteful and expensive. In their assembled state, the containers are too bulky for cost-effective return to the envelope manufacturer for reuse. Most containers are cannot be disassembled for return and reuse because they are held together with adhesives or fasteners, which cannot be removed without damaging the container. Attempts to substitute slots and tabs for adhesives and fasteners have resulted in containers that are extremely difficult to disassemble by hand. The tabs are generally bent in the process and the slots worn or torn from forcing the parts together. Such damage impairs or prevents reassembly and greatly reduces the life of the containers.

Accordingly, there is a need for an envelope container system that produces a sturdy envelope tray which is capable of withstanding hard use, that can be assembled without the need for adhesives or other fasteners, that can be easily and quickly disassembled by hand without damage to the container and that provides storage of the disassembled container in a flat configuration.

SUMMARY OF THE INVENTION

A reusable stacking tray system provides a stacking tray that can be repeatedly assembled and disassembled by hand without damage and structure for supporting the trays in a flat configuration. The stacking tray has linear structural corrugations between opposed faces. The tray includes a bottom wall bounded by spaced apart, substantially parallel side fold lines extending along the corrugations, and spaced apart, substantially parallel end fold lines extending across and at substantially right angles to the corrugations. A sidewall extends upwardly from each of the bottom wall side fold lines, and an end wall extends upwardly from each of the bottom wall end fold lines. Spaced apart slits are disposed along the side fold lines to enable the sidewalls and end walls to extend upwardly at substantially right angles from the bottom wall. The end walls are each divided into an outer portion connected to the bottom wall and an inner portion connected to the outer portion. A pair of spaced apart fold lines forms the inner and outer portion connection to provide a sturdy weight bearing surface during stacking. Spaced apart tab members extend from the end edges of the inner portion. The end fold lines each include a pair of spaced slots for receiving the tabs when the tray is assembled. The outer portion includes a hand hole and the inner portion includes a return hinge that extends transverse to the corrugations is reachable through the hand hole. The hinge allows bending of the inner portion under folding assembly and/or disassembly of the tray. The wheeled support structure includes a base and a pair of upstanding spaced apart support members. The bottom wall of each tray includes a pair of apertures for receiving the support members for stacking the trays in their flattened condition.

Various objects and advantages of this envelope tray will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this reusable envelope tray.

The drawings constitute a part of this specification, include exemplary embodiments of the envelope tray, and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a reusable stacking tray.

FIG. 2 is a perspective view showing two stacked trays containing envelopes.

FIG. 3 is a top plan view of a blank for forming a tray.

FIG. 4 is a fragmentary perspective view of an end portion of the tray showing folding to produce the tray.

FIG. 5 is a sectional view taken along line 5-5 of FIG. 1, showing operation of the hinge during assembly of the tray.

FIG. 6 is a sectional view taken along line 6-6 of FIG. 1, showing an end of the assembled tray.

FIG. 7 is a sectional view taken along line 7-7 of FIG. 1, showing operation of the hinge during disassembly of the tray.

FIG. 8 is a fragmentary view showing an end portion of a blank for an alternate embodiment of the tray including a hinge extending the full width of the end wall.

FIG. 9 is an elevational view of an alternate embodiment of the tray having partially open sidewalls.

FIG. 10 is a perspective view of a pair of trays in stacked relation, the upper tray being an alternate embodiment having a full height sidewall.

FIG. 11 is a side perspective view of a stack of flat trays on a support structure.

FIG. 12 is a perspective view of a support structure for holding and transporting flattened trays.

DETAILED DESCRIPTION

As required, detailed embodiments of the reusable envelope tray are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the device, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the apparatus in virtually any appropriately detailed structure.

As depicted in the drawing figures, the reference numeral 10 refers to a reusable envelope tray system including an improved reusable, stackable envelope-receiving container, box or tray 1 and a support structure 50 (FIGS. 1, 2, 11 and 12). A pair of trays 1 is shown in stacked relation in FIG. 2 in association with a quantity of stacked envelopes 2.

The tray 1 is formed by folding a blank 3 shown in FIG. 3, which has been cut or slit, scored with fold lines, and punched or apertured. A quantity of blanks 3 are shown in stacked relation on a support structure 50 in FIG. 11. The blanks 3 may be formed of a cellulosic material, synthetic resin, or any other foldable material. The blanks 3 are preferably taken from a corrugated stock having linear structural corrugations between opposed faces, such as for example, corrugated fiberboard, cardboard or twinwall plastic. The blank may also be of multiple wall construction such as double wall or triple wall corrugated stock. The blank 3 may also be taken from a solid sheet material such as cardboard, paperboard or synthetic resin and it is foreseen that any suitable material may be employed.

In the following description of parts of the blank 3, the references to “inner” and “outer” refer to the described parts as they will be positioned in the assembled tray configuration depicted in FIG. 1. Those skilled in the art will appreciate that certain outboard parts of the blank 3 are folded over during assembly for positioning on the inner portion of the tray 1 and likewise, certain inboard parts of the blank are positioned on the outer portion of the tray following folding assembly.

The tray 1 has an open top and a bottom wall 4 (FIG. 3). First and second opposed sidewalls 5 a and 5 b are of integral construction with the bottom wall 4 and are delineated by respective spaced apart, substantially parallel first and second sidewall fold lines 6 a and 6 b. First and second opposed end walls 11 a and 11 b are also of integral construction with the bottom wall 4 and are delineated by respective spaced apart, substantially parallel first and second end wall fold lines 12 a and 12 b that preferably extend across and at substantially right angles to the corrugations. The end wall fold lines 12 a and 12 b are substantially orthogonal or transverse to the fold lines 6 a and 6 b.

The first sidewall 5 a includes first and second flaps 13 a and 13 b that are of integral construction with the sidewall and delineated or divided by respective first and second flap fold lines 14 a and 14 b which are generally orthogonal to the fold line 6 a and to the corrugations. The second sidewall includes mirror image first and second integral flaps 15 a and 15 b delineated by respective third and fourth flap fold lines 16 a and 16 b that are generally orthogonal to the fold line 6 b as well as to the corrugations. The blank 3 is preferably cut from corrugated stock that is oriented so the corrugations are generally in overall alignment with the long axis of the tray. In such a lengthwise orientation, the relation of the corrugations to the fold lines is as previously described. It is foreseen that the blank could be cut with the corrugations in alignment with the short axis of the tray, in which case the relation of the corrugations to the fold lines would be the reverse of that previously described.

The first and second end walls 11 a and 11 b are each divided into an outer portion that is connected to the bottom wall and an inner portion that is integrally connected to the outer portion. The respective end wall outer portions or sections 21 a and 21 b are integrally connected with the bottom wall 4 and are delineated by respective first end wall fold lines 12 a and 12 b. The connection between the respective end wall inner portions or section 22 a and 22 b and outer portions 21 a and 21 b is formed by respective pairs of spaced apart fold lines. The pairs of fold lines include respective third end wall fold lines 23 a and 23 b positioned adjacent the respective outer end walls 21 a and 21 b and parallel fourth end wall fold lines 24 a and 24 b positioned adjacent the respective inner end walls 22 a and 22 b in spaced relation. The third and fourth end wall fold lines extend across and at substantially right angles to the corrugations and in parallel relation to the end wall fold lines 12 a and 12 b. In addition to providing a connection between the outer portions 21 a and 22 a and the respective inner portions 21 b and 22 b. Each pair of fold lines 23 a, 24 a and 23 b, 24 b forms a weight-bearing surface or shoulder for stacking support of one tray 1 atop another as shown in FIG. 2.

The outer wall sections 21 a and 21 b are generally rectangular in overall shape, and each includes a respective aperture 26 a or 26 b. The apertures are depicted as having a generally oval configuration (FIG. 3), although it is foreseen that any other suitable shape may be employed, such as a multilateral, circular or multiarcuate shape.

The inner end wall sections 22 a and 22 b are also generally rectangular in overall shape, and each includes a respective return hinge 31 a or 31 b extending along a portion of the length thereof. The hinges 31 a and 31 b are positioned along the respective inner end wall sections 22 a and 22 b so as to align with respective apertures 26 a and 26 b when the end walls 11 a and 11 b are folded over to form the tray 1. It is foreseen that the hinges 31 a and 31 b may also extend the full length of the inner end wall sections 22 a and 22 b, from one free side edge or margin to the other as shown in FIG. 8. The end wall inner portions 22 and 22 b may be of integral construction with the hinges 31 a and 31 b, or the hinges, such as, for example, living hinges, may be attached in covering relation over pre-formed slits in the end wall inner portions. The hinges have a return function which enables them to return from a rotated or angled position to a flattened or planar position, whether biased by a user in a counter clockwise direction toward the inside of the tray as depicted in FIG. 5 or in an opposite clockwise direction, toward the outside of the tray 1 as shown in FIG. 7.

A generally rectangular recess or cut-out portion 32 a or 32 b is disposed along the free end edge or margin of each inner end wall section 22 a and 22 b. The cut-outs 32 a and 32 b are depicted as centrally located on the respective margins, however it is foreseen that they could be positioned at any other suitable location along the margins. The end edges of the inner wall portions 22 a and 22 b also each include a pair of respective spaced tabs 33 a, 33 b and 34 a, 34 b positioned in spaced relation on either side of the respective cut outs 32 a and 32 b. It is foreseen that if the cut-outs 32 a and 32 b are repositioned, the spaced tabs 33 a, 33 b, and 34 a, 34 b could be repositioned as necessary to any other suitable location along the margins to accommodate the new positions of the cut-outs. It is also foreseen that any suitable number of tabs may be employed and that they may be appropriately spaced along the end edge of each inner end wall section 22 a and 22 b. The shoulder sections 25 a and 25 b each include a respective tab 35 a or 35 b formed by respective slit sections 36 a and 36 b. When the blank 3 is folded along the fold lines 24 a and 24 b, the tabs 35 a and 35 b pop out and away from their respective shoulders 25 a and 25 b to an upstanding position. The upstanding tabs 35 a and 35 b are aligned with the end wall portions 22 a and 22 b as shown in FIG. 1 to form a smooth, continuous surface that will not catch or damage the envelopes 2 as they are loaded into the tray 1. The sides of the slit sections 36 a and 36 b are formed generally perpendicular to the fold lines 23 a, 24 a and 23 b, 24 b to give the tabs 35 a and 35 b a generally rectangular overall configuration, thereby preventing sideways slippage of a stack of trays, especially during transport (FIG. 2).

The bottom wall of the tray 4 includes a series of spaced slots disposed along the first and second end wall fold lines 12 a and 12 b. Three slots 41 a, 41 b and 41 c are positioned along the first end wall fold line 12 a and three similar slots 42 a, 42 b and 42 c are positioned along the second end wall fold line 12 b. The outboard slots 41 a and 41 c are end wall fastening or locking slots adapted or positioned to receive respective tabs 33 a and 33 b when the end wall 11 a is folded over to assemble the tray 1. Corresponding outboard slots 42 a and 42 c are end wall fastening or locking slots adapted or positioned to receive respective tabs 34 a and 34 b when the end wall 11 b is folded over. Inboard slots 41 b and 42 b are stacking slots reserved for reception of the respective tabs 35 a and 35 b, which extend upwardly from a similar underlying tray 1 when a plurality of trays 1 is stacked in vertical relation (FIG. 2). The slots are generally rectangular in shape, with a depth greater than three times the thickness of the stock from which the blank 3 is formed, so as to include a space 58 that is generally empty or unoccupied after the tray 1 is assembled (FIGS. 5-7).

A series of spaced apart slits 43 are disposed along the fold lines 6 a and 6 b that delineate the sidewalls 5 a and 5 b from the tray bottom wall 4 (FIGS. 3, 4). The slits aid in folding assembly of the tray 1 and facilitate positioning of the sidewalls 5 a and 5 b at substantially right angles to the bottom wall 4. The tray bottom wall 4 also includes a pair of spaced apart apertures 44 for engagement with or reception of a storage stacking structure when the tray 1 is not in use. The apertures also allow air to escape when a compressed stack of envelopes is dropped into the tray 1, thereby reducing drag. The apertures 44 are preferably oval and are oriented lengthwise on the tray bottom wall 4 so that, when envelopes are positioned over the apertures 44, their bottom edges span the shorter axis of the oval as shown in FIG. 1. In this manner, the envelopes receive maximum support from the bottom wall 4. It is foreseen that the apertures 44 may also be circular, multilateral or multiarcuate or of any other suitable shape.

The sidewall end flaps 13 a, 13 b and 15 a, 15 b each include an arcuate recess or cut-out area 45 approximately centered along the end-edge or margin of the flap. The cut-outs 45 are positioned and configured so that the respective cut-outs on flaps 13 a and 15 a and on flaps 13 b and 15 b cooperate to correspond with respective apertures 26 a and 26 b to form a pair of handholds or grips when the tray is assembled. The sidewall flaps 13 a, 13 b and 15 a, 15 b each also include a second, generally rectangular recess or cut-out area 46 at the inboard portion of the end-edge or margin, positioned and configured so that the respective cut-outs on flaps 13 a, 15 a and on flaps 13 b, 15 b cooperate to correspond with respective apertures 41 b and 42 b when the tray is assembled.

FIGS. 11 and 12 depict an exemplary support structure 50 for supporting a quantity of tray blanks 3 in their flattened or unfolded configuration. The support structure 50 includes a base 51 supporting a pair of spaced apart upstanding posts 52 that are positioned for reception through the apertures 44 on the bottom wall 4 of each blank 3 when the unassembled blanks are stacked. The posts 52 may also be mounted on a wall or other vertical surface or connected to a conveyor belt or carrier unit portion of a conveyor structure. It is foreseen that the structure 50 may also be constructed to include a single post 52. While the posts 52 are depicted as being generally cylindrical or rod-shaped, they may have any suitable shape, such as, for example, an elongate rectangle or bar, and that they may be of hollow construction.

The support structure 50 includes a plurality of optional floor engaging wheels 53. A bracket 54 is connected with one side of the base 51 for mounting a tongue or vertical support 55 for use in guiding the support structure during rolling movement. A handle or grip 56 is mounted adjacent the upper end of the support 55. If a stationary structure is preferred, the wheels 53 may be equipped with locking structure (not shown), or they may be omitted entirely. It is foreseen that the bracket 54, vertical support 55 and handle 56 may also be omitted.

In use, the reusable envelope tray 1 is constructed from a blank 3 as shown in FIGS. 4-6 by a user folding the sidewalls 5 a and 5 b upwardly along the fold lines 6 a and 6 b to an upstanding position that is transverse or orthogonal to the bottom wall 4 (FIG. 4). The slits 43, which are positioned at spaced intervals along the fold lines 6 a and 6 b, facilitate this folding operation and enable the respective sidewalls 5 a and 5 b and the bottom wall 4 to subtend a substantially right angle. The user folds the flaps 13 a and 15 a along the fold lines 14 a and 16 a to a position that is orthogonal to both the bottom wall 4 and the sidewalls 5 a and 5 b (FIG. 4). Folding in this manner produces a pair of substantially right angled corners formed respectively when side 5 a subtends substantially right angles with both bottom wall 4, and flap 13 a and sidewall 5 b subtends substantially right angles with both bottom wall 4 and flap 15 a. The user next fastens or locks the corners in place by folding the end wall 11 a upwardly along the fold line 12 a (FIG. 3) and over the flaps 13 a and 15 a along respective fold lines 23 a and 24 a to bring the outer end wall section 21 a into proximity with the flaps 13 a and 15 a, thus aligning the aperture 26 a with the arcuate cut outs 45 to form a hand hold, and the inner end wall tabs 33 a and 33 b into contact with the bottom wall 4 (FIG. 5). The hand hold thus formed provides a gripping space within the end wall 11 a having a depth corresponding to the thickness of the outer end wall portions 21 a and the aligned flaps 13 a 15 a and the space 58.

The user next presses on the inner end wall section 22 a as shown in FIG. 5. This causes the inner end wall section 22 a to rotate or flex about the return hinge 31 a, with the end portion of section 22 a deflecting inwardly, toward the center of the tray 1. This shortens the effective height of the inner end wall section 22 a and enables the tabs 33 a and 33 b to slide easily and without damage along the bottom wall 4, toward the sidewall flaps 13 a and 15 a. The tabs 33 a and 33 b drop into the slots 41 a and 41 c as the end wall inner section 22 a is advanced to an orthogonal position adjacent the now inward-facing surfaces of flaps 13 a and 15 a (FIGS. 5, 6). The mating engagement of the tabs 33 a and 33 b with the corresponding slots 41 a and 41 c serves to latch the assembled tray end wall 11 a in vertical, upstanding position at a substantially right angle to the bottom wall 4. In this manner, the end wall 11 a of the assembled tray 1 has a triple layer construction with the flaps 13 a and 15 a sandwiched between respective outer and inner end wall portions 21 a and 22 a (FIG. 6). Advantageously, the inner wall portion 22 a forms a solid, inside backstop to the hand hold formed by the aperture 26 a, the arcuate cut-outs 45 and the space 58 to protect the adjacent stacked envelopes 2 from finger damage when a user lifts a loaded tray 1 (FIG. 2). The hinge 31 a now extends across the hand hole for easy access from the outside by the fingers of a user (FIGS. 2, 7).

As best shown in FIGS. 5-7, the slots 41 a and 41 c are constructed to have a depth greater than three times the thickness of the stock from which the blank 3 is constructed so as to include an empty space 58. When the inner end wall portion 22 a is folded over, this space 58 allows the associated tabs 33 a and 33 b to move past the lock points formed by the inboard margins of the openings of the respective slots 41 a and 41 c and to easily drop into place within the slots. This inward folding action in cooperation with the hinge 31 a and the space 58, provides a spring action on the inner end wall portion 22 a, urging it in an inboard direction against the lock point. As the tabs 33 a and 33 b drop into the slots 41 a and 41 c (FIG. 5) and fasten or lock the assembled end wall 11 a in an upright position, the fold lines 23 a and 24 a are brought into horizontal alignment to form a shoulder 25 a (FIGS. 4 and 6) for supporting a second tray as shown in FIG. 2. As the folding action forms the shoulder 25 a, it also causes the shoulder tab 35 a to pop into an upstanding position (FIG. 7) along the inner margin of the shoulder 25 a and in alignment with the inner end wall portion 22 a.

In the same manner, a user folds the flaps 13 b and 15 b along the respective fold lines 14 b and 16 b and folds the opposite end wall 11 b along the fold line 12 b and over the flaps 13 b and 15 b along respective fold lines 23 b and 24 b to bring the inner end wall section 22 b in proximity with the flaps 13 b and 15 b and the inner end wall tabs 34 a and 34 b into contact with the bottom wall 4. The user presses the inner end wall section 22 b into place, rotating about the return hinge 31 b, with the end portion of section 22 b deflecting inwardly. As the end wall inner section 22 b is advanced into an orthogonal position proximate or adjacent to the now inward-facing surfaces of the tabs 13 b and 15 b, the tabs 34 a and 34 b slide easily and without damage over the surface of the bottom wall 4, drop into the slots 42 a and 42 c and spring back against their inboard margins to fasten or lock the tabs 33 a and 33 b into position. The now horizontally aligned fold lines 23 b and 24 b form a shoulder 25 b for supporting a second tray or stack of trays 1, and the shoulder tab 35 b pops into an upstanding position (similar to FIG. 7) along the inner margin of the shoulder 25 b and in alignment with the inner end wall portion 22 b.

The end walls 11 a and 11 b may be folded into place simultaneously or one after the other. Once assembled, the tray 1 may be filled with envelopes 2 as shown in FIG. 2. A second tray 1 may be stacked atop the first tray 1 by aligning the tabs 35 a and 35 b with the respective slots 41 b and 42 b (FIGS. 2, 10, 13). The aligned cut-outs 46 on the sidewall flaps 13 a, 15 a and 13 b, 15 b and respective end wall inner portion cut-outs 32 a and 32 b cooperatively form a vertical space or slot in each end wall 11 a, 11 b for receiving a stacking tab 35 a or 35 b when it is inserted through the respective stacking slot 41 b or 42 b. The shoulders 25 a and 25 b of the lower tray provide strong, weight bearing surfaces for receiving the end margins of the bottom wall 4 of the upper tray. This enables a large number of trays to be stacked high on a pallet for storage and transport. Reception of the tabs 35 a and 35 b in the respective slots 41 b and 42 b serves to ensure that the trays are stacked in perfect alignment, without the possibility of slippage.

Following use, the trays 1 may be easily disassembled by reversing the steps of the method previously described. The paired arcuate cut-outs 45 of the flaps 13 a and 15 a in combination with the apertures 26 a and 26 b form a pair of hand holds that are aligned with the return hinges 31 a and 31 b when the tray 1 is assembled. The hand holds thus enable a user to access to the return hinges 31 a and 31 b from the outside of the tray 1 as shown in FIG. 7. The user disassembles a tray 1 by pushing or pressing on the return hinge 31 a with the fingers or thumb to actuate the hinge in the opposite direction previously described and crease the end wall portion 22 a, rotating it about the hinge and effectively shortening the height of the end wall portion 22 a. This causes the tab 33 a to lift or pop out of the slot 41 a without damage, enabling the user to easily unfold or pop open the end wall 11 a. In the same manner, the user pushes on the return hinge 31 b to unfold or pop open the opposed end wall 11 b.

Once disassembled, the flattened blanks 3 may be efficiently shipped back to the envelope manufacturer for reuse. The flattened blanks 3 may be transported and/or stored on a support structure 50 as shown in FIGS. 11 and 12 by aligning the apertures 44 over the posts 52 and sliding the blanks 3 downwardly to form a stack supported on the base 51. Alignment of the posts 52 and apertures 44 cooperates to hold the blanks in place on the support structure 50. The weight of the accumulated blanks 3 keeps the stack in a flattened condition on the base 51.

Advantageously, the return hinge structures 31 a and 31 b enable a user to easily and repeatedly construct and disassemble the trays 1 without damaging the inner portions 22 a and 22 b by creasing or bowing and without damaging the tabs 33 a, 33 b and 34 a, 34 b by creasing or forceful dragging across the bottom wall 4.

FIG. 9 depicts a first alternate embodiment of the tray 100 having structural features as previously described except for sidewalls 5 a′ and 5 b′ with a different geometric, configuration that that provides for open space in the center of each side. When folded to assemble the tray 100, each of the sidewalls 5 a′ and 5 b′ has an approximately right triangular configuration with the hypotenuse of each triangular portion of the respective sidewall 5 a′ and 5 b′ extending to meet the bottom wall 4′.

FIG. 10 depicts a second alternate embodiment of the tray 200 also having structural features as previously described, but having sidewalls 5 a″ (not shown) and 5 b″, each having a rectangular configuration when folded to assemble the tray 200. Each sidewall has a height equal to the height of the end walls 11 b″.

It is to be understood that while certain forms of the envelope tray have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown. 

1. A stacking tray formed from corrugated board or the like having linear structural corrugations between opposed faces: a) said tray having a bottom wall bounded by spaced apart, substantially parallel side fold lines extending along said corrugations, and spaced apart, substantially parallel end fold lines extending across and at substantially right angles to said corrugations; b) a sidewall extending upwardly from each of said bottom wall side fold lines and an end wall extending upwardly from each of said bottom wall end fold lines; and c) said end walls each being divided into an outer portion connected to said bottom wall and an inner portion connected to said outer portion.
 2. The stacking tray as set forth in claim 1 wherein: a) said inner portion includes a return hinge extending transverse to said corrugations and allowing bending of said inner portion under folding assembly and/or disassembly of said tray.
 3. The stacking tray as set forth in claim 2 wherein: a) said inner portion includes a tab extending from an end margin thereof; and b) a slot positioned along each of said bottom wall end fold lines to receive said tab member and lock said inner portion in a position transverse to said bottom wall.
 4. The stacking tray as set forth in claim 3 wherein said slot includes a space allowing said tab member to spring back against an inner margin of said slot after said tab member is received in said slot.
 5. The stacking tray as set forth in claim 2 wherein: a) a pair of spaced apart fold lines form said inner and outer portion connection to provide a weight bearing surface during stacking.
 6. The stacking tray set forth in claim 5 wherein: a) said spaced apart fold line connection includes a tab member; and b) a slot positioned along each of said bottom end wall fold lines to receive the tab member of an underlying stacking tray.
 7. The stacking tray set forth in claim 2 wherein a plurality of slits is disposed in spaced relation along each of said side fold lines to allow positioning of each said sidewall at a substantially right angle to said bottom wall.
 8. The stacking tray set forth in claim 2 wherein: a) said outer portions each include an aperture to provide a handhold of said tray; and b) said hinge is aligned with said aperture allowing bending of said inner portion by a user's hand.
 9. The stacking tray set forth in claim 2 wherein: a) said sidewalls each include a pair of spaced apart, substantially parallel sidewall fold lines extending across and at substantially right angles to said corrugations; and b) a pair of end flaps delineated by said fold lines, each of said end flaps forming a substantially right angled corner with one of said sidewalls and positioned between said outer and inner portions of said end wall of said tray.
 10. The stacking tray set forth in claim 9 wherein: a) said outer portions each include a first aperture; b) said end flaps each include an end cut-out; c) said cut-outs cooperate to form a second aperture; d) said first and second apertures are aligned to form a handhold; and e) said inner portions each form a backstop for said apertures when said tray is assembled.
 11. The stacking tray as set forth in claim 2 wherein: a) said bottom wall includes an aperture to receive a support member when said tray is in a flattened condition.
 12. A stacking tray formed from corrugated board or the like having linear structural corrugations between opposed faces: a) said tray having a bottom wall bounded by spaced apart, substantially parallel side fold lines extending along said corrugations, and spaced apart, substantially parallel end fold lines extending across and at substantially right angles to said corrugations; b) a sidewall extending upwardly from each of said bottom wall side fold lines and an end wall extending upwardly from each of said bottom wall end fold lines; c) said end walls each being divided into an outer portion connected to said bottom wall and an inner portion connected to said outer portion; d) said sidewalls each include a pair of spaced apart, substantially parallel sidewall fold lines extending across and at substantially right angles to said corrugations; e) a pair of end flaps delineated by said fold lines, each of said end flaps forming a substantially right angled corner with one of said sidewalls and positioned between said outer an inner portions of said end wall of said tray; f) said inner portion includes a return hinge extending transverse to said corrugations and allowing bending of said inner portion under folding assembly and/or disassembly of said tray; g) said inner portion includes a tab extending from an end margin thereof; h) a slot positioned along each of said bottom wall end fold lines to receive said tab member and lock said inner portion in a position transverse to said bottom wall; i) said spaced apart fold lines forming said connection include a tab member; and j) a slot positioned along each of said bottom end wall fold lines to receive the tab member of an underlying stacking tray.
 13. The stacking tray as set forth in claim 12 wherein: a) a pair of spaced apart fold lines form said inner and outer portion connection to provide a weight bearing surface during stacking.
 14. The stacking tray as set forth in claim 12 wherein: a) said outer portions each include an aperture to provide a handhold; and b) said hinge is aligned with said aperture allowing bending of said inner portion by a user's hand.
 15. The stacking tray as set forth in claim 12 wherein a plurality of slits is disposed in spaced relation along each of said side fold lines to allow positioning of each said sidewall at a substantially right angle to said bottom wall.
 16. The stacking tray as set forth in claim 12 wherein: a) said bottom wall includes an aperture to receive a support member when said tray is in a flattened condition.
 17. The stacking tray as set forth in claim 12 wherein: a) said outer portions each include a first aperture: b) said end flaps each include an end cut-out; c) said end cut-outs cooperate to form a second aperture; d) said first and second apertures are aligned to form a handhold; and e) said inner portions each form a backstop for said apertures when said tray is assembled.
 18. A stacking tray system comprising: a) a stacking tray formed from corrugated board or the like having linear structural corrugations between opposed faces: b) said tray having a bottom wall bounded by spaced apart, substantially parallel side fold lines extending along said corrugations, and spaced apart, substantially parallel end fold lines extending across and at substantially right angles to said corrugations; c) a sidewall extending upwardly from each of said bottom wall side fold lines and an end wall extending upwardly from each of said bottom wall end fold lines; d) said end walls each being divided into an outer portion connected to said bottom wall and an inner portion connected to said outer portion; e) said inner portion includes a return hinge extending transverse to said corrugations and allowing bending of said inner portion under folding assembly and/; or disassembly of said tray; f) a tray support structure having a post connected to a base; and g) said bottom wall including an aperture for receiving said post to support said tray in a flattened condition.
 19. The stacking tray system as set forth in claim 18 wherein: a) said support structure includes a plurality of wheels.
 20. The stacking tray system as set forth in claim 19 wherein: a) said support structure includes a handle. 